Falcon Marine specializes in the development of manufacturing processes and procedures for the production of composite products
Complete project management, customer support and communication.
Our 40,000 sq ft manufacturing floor, backed by dedicated engineering and program management support, carries composite projects from early concept definition through repeatable production.
Design, CAD, prototyping and project management
Clients can engage Falcon Marine before final engineering is complete. Our design and engineering team turns early concepts into buildable, budget-aware prototypes and production plans.
01
Engineering and design project management
Dedicated project leads coordinate design reviews, vendor communication and timelines from kickoff to delivery.
02
Product models, 3D CAD drawings and/or mock ups and full prototype components
CAD development and mockups validate form, fit and function before committing to tooling.
03
Budget development, scheduling, and milestone tracking
Transparent budgets and milestone tracking keep programs on schedule and within scope.
04
Prototypes, molds, one-off parts, and complete assemblies
In-house fabrication produces prototype parts, molds and one-off assemblies for early evaluation.
Tooling and fiberglass composite production
Falcon Marine develops tooling and closed-mold composite production methods for clients that need consistent private-label parts, assemblies, and production support.
01
Controlling costs during the build process without compromising the integrity
Tooling strategy is planned around part geometry and volume to keep builds cost-efficient and structurally sound.
02
Infusion process allows for a cleaner environment by using closed molds
Closed-mold fiberglass composite manufacturing produces consistent, repeatable laminates for parts and assemblies.
03
Complete project management, customer support and communication
Repeatable private-label production is backed by consistent communication and hands-on project oversight.
Falcon Marine can support prototype, one-off, and ongoing production needs, matching tooling and process to each project's requirements.
Composite materials and manufacturing processes
Falcon Marine offers a broad range of closed-molding processes, reinforcements, resin systems, and core options so a composite build can be matched to structural, cosmetic, and production requirements.
| Category | Available Options |
|---|---|
| Processes | Infusion, Vacuum Bag, RTM, VARTM, Light RTM, and PrePreg |
| Reinforcements | Glass, Carbon, Kevlar, and other exotic reinforcements |
| Resin Systems | Polyester, Vinyl Ester, Epoxy, Phenolic, and Polyurethane |
| Core Options | components may be cored or non-cored; thermoformed core materials for curved geometries; foam-injection capable. |
Closed molding is a controlled process that encloses resin during fabrication, rather than a single method suited to every project; the right process depends on part geometry, finish, and structural requirements.
The project path, start to finish
From initial design through mockups, prototype, testing, full production and warranty service.
01 Initial requirements and quality points
Requirements, quality points and expectations are defined at the outset.
02 Engineering and design
Engineering and design work translate requirements into a buildable plan.
03 Mockups and prototype components
Mockups and prototype components validate the design before tooling commitments.
04 Testing and refinement
Testing and refinement confirm performance and fit ahead of production.
05 Full production
Full production proceeds against the agreed schedule and specification.
06 Warranty service and ongoing support
Warranty service and ongoing support follow delivery of completed parts and assemblies.
This path is designed to align budget expectations, schedules, and milestone points before production begins.
Frequently asked questions
Quickly confirm Falcon Marine's project scope, technical readiness, and production support.
Can Falcon Marine help before my drawings are complete?
Yes. Clients can engage Falcon Marine before final engineering is complete, using product models, 3D CAD drawings and/or mock ups and full prototype components to develop the design.What composite processes and materials are available?
Falcon Marine works with Infusion, Vacuum Bag, RTM, VARTM, Light RTM, and PrePreg processes, along with glass, carbon, Kevlar, and other exotic reinforcements and a range of resin systems.Are prototypes, molds and one-off parts supported?
Yes. Falcon Marine supports prototypes, molds, one-off parts, and complete assemblies as part of the design and production process.How does Falcon Marine support moving from prototype to repeatable production?
Tooling development and closed-mold production methods, combined with complete project management, customer support and communication, carry a project from prototype into repeatable production.
Ready to discuss your project?
Our facility is ready to help. Talk to one of our project designers about your ideas. We can discuss design assistance, manufacturing method development, and project requirements.
